HUSTLER TrimStar General Service Manual
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HUSTLER TrimStar General Service Manual

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114674_0512
Hustler
General Service Manual
®
TrimStar
•••••
P.O. Box 7000
•••
Hesston, Kansas
•
67062-2097
REV B

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Summary of Contents for HUSTLER TrimStar

  • Page 1 Hustler ® TrimStar General Service Manual ••••• P.O. Box 7000 ••• Hesston, Kansas • 67062-2097 114674_0512 REV B...
  • Page 2 WARNING WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective working order.

  • Page 3: Table Of Contents

    Table of Contents General Information ........1-1 Safety.
  • Page 4 REV B 114674_0512...

  • Page 5: General Information

    Daily inspect mower for grass clippings and wire and string ® This manual is part of a service package for the Hustler tangles. The underside of the mower deck will collect a build-up TrimStar mowers. Use of this manual in conjunction with other of grass clippings and dirt, especially when grass is wet or has ®...
  • Page 6 REV B 114674_0512...

  • Page 7: Safety

    SAFETY • Use extreme care when handling gasoline and other fuels. They are extremely flammable and vapors are explosive. A fire or explosion from fuel can burn you and others and can damage property. • Refuel outdoors. Never refuel or drain the fuel from the This safety alert symbol is used to call attention to a message machine indoors.
  • Page 8  Repairs or maintenance requiring engine power mower blades are extremely sharp. Wrap the blade(s) or wear gloves and use extra caution when servicing them. should be performed by trained maintenance person-  Use only genuine Hustler ® nel only. Turf Equipment replacement ...
  • Page 9  Never use an open flame as light anywhere on or around • Electrolyte may overflow and damage paint, wiring or the equipment. structure. When cleaning the battery, use soap and  When preparing engine for storage, remember that fuel water.
  • Page 10 REV B 114674_0512...

  • Page 11: Torque

    TORQUE Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Special Torques section. Size Ft-lbs Size...
  • Page 12 REV B 114674_0512...

  • Page 13: Power Unit Maintenance

    POWER UNIT MAINTENANCE Steering Adjustments 3. Remove brake link from lower brake bell crank. Figure Steering neutral adjustment The mower’s steering has been factory adjusted to eliminate creeping when the H-Bar steering lever is in the neutral position. However, should the mower begin to creep, the steering control linkage can be adjusted.
  • Page 14 Disengage Engage Neutral lock lever Locking hardware Steering rod assembly Figure 4-3 12. Wheels should both return to neutral when the H-Bar 2. Raise the rear of the mower and block with certified jack steering lever is pulled forward out of reverse. If not, stands.
  • Page 15 Any of these will destroy the belt composition in a very short time. Pump Clutch Belt Adjustment The TrimStar mower is equipped with a pump clutch that Tension idler disengages the pump clutch belt. When the belt is disengaged, the engine will start easier in colder temperatures.
  • Page 16 Hydraulic expansion tank Screw Filter guard Screw Figure 4-9 11. Fill with 20W50 motor oil until oil just appears at the bottom of each transaxles top port (approximately 2 qts. per transaxle). Install the top port plug into each transaxle Figure 4-7 as the oil level reaches this port.
  • Page 17 Gauge wheels..... 8-12 psi (55-83 KPa) ® slowly move the H-Bar steering lever in both forward Solid fill tires are not recommended for Hustler TrimStar and reverse directions (5 or 6 times). Check the oil level, mowers.
  • Page 18 REV B 114674_0512...

  • Page 19: Engine Maintenance

    Engine Air Filter number 11010000 and 12010641, have a fuel evaporation sys- tem filter. Non-domestic TrimStar mowers (units with a CE or Perform engine air filter maintenance per the engine’s EX extension after the model number) manufactured after serial number 12010641 do not have a fuel evaporation system filter.
  • Page 20 Fuel & evaporative system line routings There are two rubber hoses that are connected to the fuel tank. One is the fuel hose that is part of the fuel system. The other is the vapor line that is part of the fuel evaporative system. The fuel hose is connected to the port on the side wall of the Fuel evaporation fuel tank.
  • Page 21 Engine RPM Settings The engine rpm’s are set at the factory for maximum mowing efficiency. Occasionally it may be necessary to check and adjust the settings. The engine speeds should be set as follows: Kawasaki FS481 / FS541 / FS600 ENGINE SPEED MODEL NO.
  • Page 22 REV B 114674_0512...

  • Page 23: Deck Adjustments

    DECK ADJUSTMENTS Deck Leveling – 48”/54” Side Discharge Deck so that the bar has play. Figure 6-2 7. Start the leveling process on the left front of the mower. Leveling the deck must be done in the following manner and 8.
  • Page 24 Clamp Nuts Deck lift here Deck stop Nuts bracket 1.0” Deck adjustment stop Nuts Deck lift 1.0” 5/16” bolt Nuts Adjuster Jam nut Hardware Figure 6-2 Deck Leveling – 36” Side Discharge Deck Block Leveling the deck must be done in the following manner and Block order: 1.
  • Page 25 Clamp here Adjuster 5/16” bolt Deck stop Jam nut bracket Deck adjustment stop 1.5” Nuts Deck lift Nuts Figure 6-4 13. Loosen the jam nut on the adjuster, and back the 5/16” Gauge wheels tire pressure..8 - 12 psi bolt out to allow the adjuster to move up and down freely.
  • Page 26 4. Place the height stop in the 3” (7.62cm) hole, with the flat on all four blocks. Figure 6-6 side of the height adjusting stop against the deck stop 6. Loosen the two nuts on the front of height indicator bar bracket.
  • Page 27 inflated before starting to level deck. The recommended pressures are as follows: 3.40” Block Drive wheels tire pressure ..8 - 12 psi 3.16” Gauge wheels tire pressure ..8 - 12 psi WARNING Stop engine.
  • Page 28 deck support blocks. WARNING 15. Tighten the other nut on the opposite side of the block, and jam them tightly together against the block. 16. Go to the left front of the mower. 17. Make sure that there is still slack in the chain. If not, Never work with blades while engine is running or deck loosen the two nuts on the block holding the threaded rod clutch switch is engaged (on).
  • Page 29 NOTE: A blade ® holding tool (part number 381442) is available from Hustler Belts Turf Equipment. It is designed to prevent the blades from rotat- ing when they are being removed or installed on the spindle.
  • Page 30 for a badly worn belt or pulley. Spring chain Spring chain Spring chain anchor point Spring chain anchor point Idler spring Idler spring 36” Side Discharge Deck 36” Rear discharge Figure 6-12 deck available as a CE mower only. 36” Rear Discharge Deck Spring chain Spring chain Figure 6-14...
  • Page 31 Deck Belt Routing & Tensioning NOTE: The following notes are the same for all the different decks shown. 1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3¼" cut height. 2.
  • Page 32 54" Side Discharge Deck 5.5” – 6.0” Figure 6-18 36" Rear Discharge Deck 36” Rear discharge deck available as a CE mower only. 5.5” – 6.0” Figure 6-19 REV B 6-10 114674_0512...
  • Page 33 48" Rear Discharge Deck 5.5” – 6.0” 48” Rear discharge deck available as a CE mower only. Figure 6-20 114674_0512 6-11 REV B...
  • Page 34 REV B 6-12 114674_0512...

  • Page 35: Electrical

    ELECTRICAL Electrical Schematic – Recoil Start 114674_0512 REV B...
  • Page 36 Electrical Schematic – Electric Start REV B 114674_0512...

  • Page 37: Maintenance Schedule

    MAINTENANCE SCHEDULE Hustler TrimStar ® Maintenance Schedule Refer to Figure 8-1, Figure 8-2, Figure 8-3, Figure 8-4, Figure 8-5, Figure 8-6 & Figure 8-7 WEEKLY MONTHLY ANNUALLY SERVICE AT OR 50 OR 100 OR 300 INTERVALS INDICATED HOURS HOURS HOURS...
  • Page 38 Maintenance Locator Chart Figure 8-1 Figure 8-2 Figure 8-3 1. Engine oil fill & dipstick 2. Fuel filter 3. Engine air cleaner 4. Engine oil drain 5. Fuel tank 6. Engine oil filter 7. Drive tire 8. Gauge wheel bearings 9.
  • Page 39 Figure 8-6 48” Rear Discharge Deck 1. Engine oil fill & dipstick 2. Fuel filter 3. Engine air cleaner 4. Engine oil drain 5. Fuel tank 6. Engine oil filter 7. Drive tire 8. Gauge wheel bearings Figure 8-7 9. Blades 10.
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  • Page 41: Troubleshooting

    TROUBLESHOOTING SUGGESTED SUGGESTED SYMPTOMS PROBABLE CAUSES SYMPTOMS PROBABLE CAUSES REMEDIES REMEDIES Mower creeps when Disengage deck Steering linkage Deck clutch engaged H-Bar steering lever Adjust linkage clutch needs adjustment is in neutral No fuel or line Fill tank or replace Steering linkage Adjust linkage plugged...
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  • Page 43 INDEX PAGE PAGE Belts ..............4-2 Maintenance Precautions ........2-2 Blades ..............6-6 Maintenance Schedule .......... 8-1 Carbon canister ............5-1 Mower blade maintenance ........6-6 Deck Belt adjustment ..........6-7 Mower blade removal ..........6-7 Deck Belt Routing & Tensioning ......6-9 Operate Machine Safely ........2-2 Deck leveling ............6-1 Operation Precautions ...........

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